Abstract
Click ‘Lean’’ approach has been applied more than frequent in many manufacturing management floors over these few decades. Started
in the automotive industry, sequential improvement initiatives were implemented to enhance the manufacturing practice changes. The
team described a case where Lean Production (LP) principles were adapted for the process sector of an automotive part manufacturing
plant. Value Stream Mapping (VSM) is one of the key lean tools used to identify the opportunities for various lean techniques. The
contrast of the before and after the LP initiatives in determine managers potential benefits such as reduced production lead-time and lower
work-in-process inventory. As VSM involves in all of the process steps, both value added and non-value added, are analyzed and using
VSM as a visual tool to help see the hidden waste and sources of waste. A Current State Map is drawn to document how things actually
operated on the production floor. Then, a Future State Map is developed to design a lean process flow through the elimination of the root
causes of waste and through process improvements. An Implementation Plan then outline details of the steps needed to support the LP
objectives. This paper demonstrates the VSM techniques and discusses the application in an LP initiative on a product (Front disc, D45T)
case study.